21 价值流(精益生产)

1LeanSigma2價值流是什麼?價值流就是為滿足客戶要求，當前流程所必需的所有行為和活動（增值和非增值的）。Avaluestreamisalltheactionsandactivities(valueaddedandnon-valueadded)requiredbythecurrentstateoftheprocesstomeetthecustomerdemand.23流動研發工程訂單錄入&計畫運作銷售&市場財務客戶價值4什麼是價值流圖？Avaluestreammapisapreciselivingdocumentthatallowsustoseeandunderstandtheflowofinformationandmaterialasa„product‟or„service‟movesthroughthevaluestream.價值流圖是精確且靈活的文件，讓我們了解我們的產品或服務在價值流中流動的物料流與信息流。一個考慮物料和資訊怎樣貫穿整個流程的流程圖！3Information信息流物料流客戶價值研發工程訂單錄入&計畫運作銷售&市場財務價值流5LeanSigma高端流程圖定位關鍵特性或流程通常關注流程順序特點是從一個流程步驟到下一個流程步驟的線性流程跟隨流程順序，但通常缺乏新員工能成功的完成任務的細節詳細流程圖明白流程運作的細節，決定點通常關注工作區域一到兩個流程用於工作指引用於失效模式分析和控制計畫跟隨流程圖能很好地完成任務不同水準的結構圖!6LeanSigma4研發工程訂單錄入&計畫運作銷售&市場財務信息流物料流Information流程步驟1流程步驟2流程步驟3流程步驟4客戶價值內部客戶不同層次的流程圖7LeanSigma8價值流案例“LearningtoSee”byRother,Shook59價值流案例Customer/ElPasoASBizOpsMasterSchedulerMRPIISuppliersWarehouseCustomerDemandReceivingInspectionOrder/ForecastASPurchasingPlenumassyDuctsBracketsNozzleassyExpenseitemsEtc...PurchasedPartsWaterSeparatorsCell5SteelHeatExchanger(ASAM)Cell16Cell11PackAssyCell12TurbomachineryCell24Cell7TurboKitsPurchaseOrdersWaterSeparatorKitPackAssyKitMexicoKitCellPlannerCellPlannerCellPlannerCellPlannerEnvironmentControlPackHighLevelProcessMap當你沿著物流與資訊流的路徑走過並觀察時，要不斷收集當前狀況的情報。首先沿著出口到入口的價值流，快速地走上一遍，了解整個流程和各個工程。然後再走一次，收集每個工程的詳細資料。應當由出貨端開始，朝價值流的上游追溯，而不是從收貨端開始朝下游推進。這樣，你可以從與顧客聯繫最緊密的工程開始繪圖，位上游的其他工程訂下節拍。帶著碼表，不要信任那些標準時間或不是親自量測的情報。即使有好幾個人一起參加價值流圖的準備工作，還是要有一個人獨力完成整個價值流圖的繪製，以全面瞭解整個價值流圖。最後，使用鉛筆手工繪圖。繪製價值流圖的要訣1061.Drawiconsrepresentthecustomerandthesupplier.繪製代表客戶和供應商的符號Usethesameicontorepresentthecustomerandthesupplier.使用相同的符號來表示，客戶和供應商11繪製價值流圖1271.Drawiconsrepresentthecustomerandthesupplier.繪製代表客戶和供應商的符號Usethesameicontorepresentthecustomerandthesupplier.使用相同的符號來表示，客戶和供應商Drawthecustomericonintheupperrightcorner.把顧客的符號放在右上角Drawthesuppliericonintheupperleftcorner.把供應商的符號放在左上角Drawtheproductioncontroliconbetweenthecustomerandthesuppliericons.把生產控制中心的符號放在中間13繪製價值流圖1482.Drawthedataboxbelowthecustomericon,andenterthecustomerrequirementsinit.Includemonthlyanddailyrequirementsofeachproduct,andthenumberofcontainersrequiredperday.繪製databox並且寫入需求產品和數量，以及批量(貨櫃數)。15繪製價值流圖1693.Entershippingandreceivingdata:Drawatruckiconbelowthecustomericon,andenterinsidethetruckiconthedeliveryfrequency.(Howoftendoesthecustomerrequireshipments?)在顧客符號下方繪製卡車，並且寫下運送頻率。17繪製價值流圖18103.Entershippingandreceivingdata:Drawatruckiconbelowthecustomericon,andenterinsidethetruckiconthedeliveryfrequency.(Howoftendoesthecustomerrequireshipments?)Drawashippingiconbelowthecustomertruck.在卡車下繪製一個ship符號19繪製價值流圖Ship3.Entershippingandreceivingdata:Drawatruckiconbelowthecustomericon,andenterinsidethetruckiconthedeliveryfrequency.(Howoftendoesthecustomerrequireshipments?)Drawashippingiconbelowthecustomertruck.Drawadirectionarrowfromtheshippingicon,throughthecustomertruck,tothecustomericon.繪製一個箭頭，從ship穿越卡車到顧客符號。20繪製價值流圖113.Entershippingandreceivingdata:Drawatruckiconbelowthecustomericon,andenterinsidethetruckiconthedeliveryfrequency.(Howoftendoesthecustomerrequireshipments?)Drawashippingiconbelowthecustomertruck.Drawadirectionarrowfromtheshippingicon,throughthecustomertruck,tothecustomericon.Drawatruckiconbelowthesuppliericon,andenterinsidethetruckiconthedeliveryfrequency.在顧客符號下方繪製卡車，並且寫下運送頻率。21繪製價值流圖3.Entershippingandreceivingdata:Drawatruckiconbelowthecustomericon,andenterinsidethetruckiconthedeliveryfrequency.(Howoftendoesthecustomerrequireshipments?)Drawashippingiconbelowthecustomertruck.Drawadirectionarrowfromtheshippingicon,throughthecustomertruck,tothecustomericon.Drawatruckiconbelowthesuppliericon,andenterinsidethetruckiconthedeliveryfrequency.Drawadirectionarrowfromthesupplier,throughthesuppliertruck,totheplacewhereyouwilldrawaniconrepresentingthemostupstreamprocessinthevaluestream.繪製一個箭頭，從供應商通過卡車到價值流的上方。22繪製價值流圖124.Drawthemanufacturingoperationsalongthebottomofthemap,withthemostupstreamprocessontheleftandthemostdownstreamprocessontheright.Representeachprocesswithanicon,labelit,anddrawdataboxesbeloweachprocessicon.Addanotchedlinebelowtheprocessboxesonwhichyouwillrecordtheproductiontimeline.在圖的底部繪製工廠流程，最左邊是第一個流程，最右邊是最後一個，之後把中間補齊。在每一個流程中寫入名稱，每一個流程下面放一個數據圖。最後在底部放一個缺口圖。23繪製價值流圖4.Drawthemanufacturingoperationsalongthebottomofthemap,withthemostupstreamprocessontheleftandthemostdownstreamprocessontheright.Representeachprocesswithanicon,labelit,anddrawdataboxesbeloweachprocessicon.Addanotchedlinebelowtheprocessboxesonwhichyouwillrecordtheproductiontimeline.將製程畫在價值流圖的下半部，製程上游在左，下游在右，以符號代表各個製程，並在各製程下方繪製資訊盒，最後在資訊盒下方繪製凹凸線，紀錄製造所需時程。Determinethenumberofboxesyouwillneedaheadoftimetobesureyouleaveenoughspaceforallofthem.要先決定有多少製程。Alwaysplacetheshippingiconatthefarendoftheprocesschain–directlybelowthetruckiconforthecustomer.一定要在製程末端繪製ship符號。Leaveenoughspacebetweeneachboxfordata.Ifmaterialisstoredorstandsidlebetweenprocess,forexample,youwillneedtoleavespacebetweenprocessiconstonotethisandtheWIPamounts.在各資訊盒之間留下足夠的空白。若半成品在製程之間有庫存或閒置的狀況，在製程符號之間的空白處紀錄下來。24繪製價值流圖135.Enterprocessattributesinthedataboxy